Awning structure, and method of assembly

ABSTRACT

An awning structure including a horizontal mounting strip with an outwardly opening curved recess, and a generally U-shaped hat section having an arcuately curved attachment flange which is received within the mounting strip recess in a water-tight pivotal supporting relationship. A hat section made of two parts including a hanger, and a flashing which is pivotally mounted on the hanger. The method of assembling the awning structure in which the flashing is progressively rotated downward above the pans and secured thereto.

Uited States Patent Dunn Mar. 11, 1975 [54] AWNING STRUCTURE, AND METHOD OF 3,234,697 2/l966 Toti et a]. .0 52/75 ASSEMBLY FOREIGN'PATENTS OR APPLICATIONS [76] In entor: R- S- unn, 2 S- i en p 607,709 11/1960 Canada .[52/58 201, Los Angeles, Calif. 90057 22 d: l 23 1973 Primary ExaminerFrank L. Abbott 1 le y Assistant ExaminerJames Li Ridgill, Jr. [21] Appl. No.: 381,804

[57] ABSTRACT Cl 2/ 5 /6 An awning structure including a horizontal mounting [5 1] Int. Cl. E04b 1/344, E04b 7/16 strip with an outwardly opening curved recess, and a [58] Field of Search 52/73-78, 588, generally U-shaped hat section having an arcuately 52/ 97 curved attachment flange which is received within the mounting strip recess in a water-tight pivotal support- [56] References Cited ing relationship.

UNITED STATES PATENTS A hat section made of two parts including a hanger, l,l70,69l 2/1916 Skipworth 52/588 and a flashing which is pivotally mounted on the 1,4l9,287 6/l922 Maxwell 1 52/60 hanger. The method of assembling the awning 2,062 l60 1 H1936 Calkins et al. 52/588 structure i whi h the flashing is progressively rotated 2,593,221 4/1952 Thompson et all 52/76 downward above the pans and Secured thin-ero- 2.663318 12/1953 Pollock 52/58 2,746.537 5/1956 .loslin 52/71 6 Claims, 5 Drawing Figures AWNING STRUCTURE, AND METHOD OF ASSEMBLY BACKGROUND OF THE INVENTION It is now well known to form an awning structure by utilizing a number of metal pans, each of which has a generally U-shaped cross section, by'arranging the pans in side-by-side relationship and attaching them together. The side walls of-the pans are conventionally manufactured to provide an interlocking relationship which prevents leakage of water between the pans. One end of all of the pans is then supported in an elevated position so that any water falling on the structure will run by gravity in a direction lengthwise of each one of the pans. Awning structures of this type are now widely used, particularly in conjunction with mobile homes.

The elevated end of the awning structure is usually supported from the wall of an appurtenant structure, such as a mobile home. Additional structural elements are then needed in order to support and seal the upper end of the awning, and these additional elements may include a mounting strip and a hat assembly.

In the prior art the hat assembly has generally included an elongated hanger which is supported from the mounting strip or rail and which in turn supports the under surfaces of the awning pans; and a flashing which extends above the elevated pan ends.

Based upon careful observation of the conventional upper end support for an awning structure of the type described, I have concluded that improvement would be desirable and is possible.

One object of the present invention, therefore, is to provide an improved assembly for supporting the elevated end of an awning structure.

Another object of the present invention is to provide a novel method of assembling an awning structure, particularly the hat assembly thereof.

SUMMARY OF THE INVENTION According to the present invention an elongated hanger which extends along and underneath the elevated pan ends is still used, the same as in the prior art. This hanger is supported from the wall of the appurtenant structure by means of a mounting strip or rail but the hanger and mounting strip are uniquely designed to provide a leak-proof pivotal locking arrangement. According to my invention a flashing is also used to extend above the elevated ends of the pans, and this flashing is constructed in a unique and novel manner.

Furthermore, in accordance with my invention the method of assembling the awning structure, and particularly the hat assembly thereof, is a great deal different than any that has heretofore been known.

More specifically, according to my invention, the flashing is made to interlock directly with the hanger. The hanger is provided with a joining portion, located at the upper corner of the elevated ends of the awning pans, which joining portion is laterally curved through an angle of at least about 180. The flashing is made as a flat sheet which covers the upper surface of the elevated ends ofthe pans, and also includes ajoining portion integrally formed with one lateral edge and which is adapted to be received in a nested and pivoted relationship within the joining portion of the hanger. The joining portion of the hanger locks in a similar manner with an arcuately curved recess of the mounting strip.

Furthermore, according to my invention, it is preferred to construct the flashing in sheets or sections, so that a number of flashing sheets are arranged in a longitudinal series to be supported from a single elongated hanger. Furthermore, the flashing, sheets are constructed in such a way that their ends will overlap, thus providing an effective water tight seal.

One advantage of my invention is that an effective water-tight seal is achieved, which has not been possible with the type of upper end support utilized in the prior art awnings.

Another advantage of my invention is that the installation may be completed without the necessity for the installer to walk on top of the awning structure. The attendant risk of damage to the structure is thereby avoided.

Still another important advantage resulting from my invention is that the labor time required for installing the awning structure is significantly reduced.

DRAWING SUMMARY FIG. 1 is an eleva-tional cross sectional view of an awning structure in accordance with the present invention;

FIG. 2 is a cross sectional view taken on the line 22 of FIG. 1;

FIG. 3 is a fragmentary cross sectional view taken on line 33 of FIG. 2;

FIG. 4 is an exploded perspective view of the mounting strip and hat assembly; and

FIG. 5 is an end view of the mounting strip and hanger.

PREFERRED EMBODIMENT Reference is now made to the drawing, FIGS. 1 through 5, inclusive, illustrating the presently preferred form of the invention.

The awning structure is made from a plurality of pans P which are placed in side-by-side relationship with their elevated end being supported from the wall W of the appurtenant structure. FIG. 2 shows pan Pl at one side of the awning, the adjoining pan P2, and a portion of pan P3. Each of the pans has a flat bottom wall 60, an inner side wall 61, and an outer side wall 62. The inner side wall 61 is characterized by a joining portion 61a which is bent over inwardly of the pan. The outer side wall 62 is characterized by a joining portion 62a which is bent over in a direction outwardly of the pan. Therefore, as shown in FIG. 2, the joining portion 610 of pan P2 and the joining portion 62a of pan P1 are interengaged in a secure relationship which also prevents any leakage of water between the pans P1 and P2.

The elevated end of the pans P is supported from the wall W by means of a mounting strip 10 and hat assembly HA. These parts are shown in a fragmentary exploded perspective view in FIG. 4, and also shown in a cross-sectional view in FIG. 1.

The parts of the hat assembly HA are a hanger 20, and a flashing 30. There is a mounting strip 10 which goes the full length of the awning structure, i.e., the cumulative total width of all of the pans P. In similar fash ion hanger 20 the full length of the awning structure. The flashing 30 consists of one or more sheets arranged in a longitudinal sequence, and hence in some of the views these different sheets or sections are designated as 30a, 30b, and 30c, respectively.

The mounting strip or rail includes a flat side 11 and a joining side 12. The joining side 12 is laterally curved through an angle of at least 180. The flat side 11 of the mounting strip is fastened to wall W by means of screws 15. In the particular illustration the flat side 11 is below the joining side 12, but inverse arrangement may be employed if desired. A strip of caulking material 17 is placed above the mounting strip 10 to prevent any leakage of water between strip 10 and wall W.

The hanger 20 includes "a joining portion 21, a vertical panel 22, and a horizontal panel 23. The panels 22, 23 together constitute the pan retaining or supporting portion of the hanger. Panel 23 supports the under surface of pans P, while vertical panel 22 extends across and closes the otherwise open ends of the pans. The joining portion 21 extends from the upper edge of vertical panel 22, and is therefore located at the upper corner of the elevated ends of pans P. The outer edge of horizontal panel 23 is also provided with a downwardly depending flange 24.

In asembling the awning the mounting strip 10 is first placed in its proper position and fastened down by means of the screws 15. Caulking material 17 is preferably added at this time. Then the hanger 20 is positioned by sliding its joining portion 21 longitudinally into the joining portion 12 of mounting strip 10. See FIG. 5. It will be noted that joining portion 21 is adapted for a tight, pivoting nesting relationship with the joining side 12 of mounting strip 10. When the hanger has been inserted in the full length of .the mounting strip it is then rotated downward, as indicated by the arrow in FIG. 5.

Several pans are now attached together in side-byside relationship, and their outer ends (not shown) are placed upon a suitable supporting structure. The elevated ends of the pans are placed upon hanger 20. Screws 25 are now used to fasten the bottom walls 60 of the various pans to the horizontal panel 23 of the hanger 20. This results in securement of the pans P and also establishes the angular position of the hanger 20.

Prior to assembling additional pans into the awning structure, the next step is to commence the installation of the flashing by placement of the first flashing sheet or section. Since the flashing structure is unique it will now be described in detail.

Each flashing sheet is integrally formed from a single flat sheet of metal. It includes a rectangular body or panel 32 which is the pan covering portion of the flashing. It also includes a joining portion 31 which is laterally curved in order to nest within the joining portion 21 of hanger 20 in an interlocking relationship. The joining portion 3] of each flashing sheet is made somewhat shorter than the rectangular body or panel 32. More specifically, as shown in FIG. 4 the rectangular body 32 extends somewhat beyond the joining portion 31 on both ends thereof.

The first flashing sheet 30a is raised at an angle and its joining portion 31 is then inserted into the joining portion 21 of hanger 20. The flashing sheet is then rotated downward until it rests upon the upper surfaces of the pan ribs, specifically, the joining portions 61a and 62a of pan Pl. It is then secured to the ribs by means of screws 35, 36.

The rectangular body 32 of the flashing sheet together with panels 22 and 23 of the hanger form a U- shaped structure which completely encloses the elevated end of the pans. Because of the secure interlock of joining portion 31, joining portion 21, and joining side 12, this structure is very well sealed against the entrance of water. It may, however, be desired to utilize a filler pad 50 made of foam plastic material or the like, to block off the end of each pan at a point which lies beneath the flashing. Filler pad 50 is shown in FIG. 1. When filler pad 50 is to be used it is preferably installed prior to rotating the flashing downward to its final position of rest.

After one flashing sheet has been installed, it is then convenient for the installer to place one or more additional pans in their proper positions and secure them in place. Then a second flashing sheet may be installed. The second flashing sheet 30b is inserted at an angle and is slid longitudinally of the hanger 20 until its joining portion 31 butts against the joining portion 31 of flashing sheet 30a. Then the flashing sheet 30b is rotated downward into place. This results in an overlapping relationship between the rectangular body of the second flashing sheet and the rectangular body of the first flashing sheet. Specifically, the end of flashing sheet 30b overlaps the end of flashing sheet 30a. Flashing sheet 30b is then fastened down with screws 35, 36.

The construction of the awning is then continued in this manner until it is completed. The pans are added one, two, three, or four at a time. Then one or two flashing sheets are added. Then more pans are installed. The exact procedure depends upon the width of the pans, the length of the flashing sheets, and the arm length of the installer. The significant advantage of this procedure is that the installer need not walk on top of the awning structure in order to install the flashing. Furthermore, he need not manipulate a lengthy and bulky flashing.

The hanger need not be inserted lengthwise into the mounting strip but may be inserted from the side, then rotated down as shown in FIG. 5.

The flashing may if desired be formed as a single section, and it may be progressively rotated downward along its length and secured, as successive pans are installed.

In order to comply with the patent laws the invention has been described in one of its forms in considerable detail. However, the concept and scope of the invention are to be limited only in accordance with the following claims.

I claim:

1. An awning structure attached to the wall of a preexisting building comprising, in combination:

a mounting strip extending horizontally along the wall of the building, said mounting strip having a curved recess opening outwardly from the building;

means attaching said mounting strip to the building wall, and providing a water-proof seal between the mounting strip and the wall;

a plurality of generally trough-shaped pans arranged in a side-by-side relationship having the upper edges of their inner end approximately aligned with said recess of said mounting strip, and inclining outwardly and somewhat downwardly so that their outer ends may be supported by other means, the adjacent ones of said pans being joined together by means of overlapping and interlocking edges which provide an essentially water-proof joint between them;

and a hat assembly for securing the inner ends of said pans to said mounting strip, while concurrently permitting the upper ends of said pans to pivot relative to said mounting strip in response to wind pressure and the like without breaking said seal, said hat assembly including:

a. an elongated hanger having an arcuately curved flange received within said recess of said mounting strip, a flat portion extending downwardly from said flange to close the inner ends of said pan, and a lower flange bent outwardly from said main section of said hanger and secured to the bottom edges of the pans; and

b. an elongated flashing having an arcuately curved flange received within said flange of said hanger, said flashing having a flat portion extending over the upper edges of said pans whereby said hanger and said flashing together comprise a U-shaped box which encloses the upper ends of said pans and is capable of pivoting as a unit relative to said mounting strip;

said hanger flange and said flashing flange forming a water-tight joint with said mounting strip.

2. In an awning .structure having a horizontal mounting strip attached by a water-proof seal to the outer wall of a building and a plurality of generally troughshaped pans extending perpendicular to the mounting strip and arranged in side-by-side relationship with their abutting edges secured by water-proof joints, a hat assembly for providing water-proof enclosure of the upper ends of said pans while concurrently supporting said pans from said mounting strip in a pivotally yieldable but leak-proof connection thereto, said hat assem bly comprising, in combination:

a hanger having a flat rectangular main body portion adapted to be substantially vertically disposed and to extend across the upper ends of said pans to provide an enclosure thereof, said hanger also having an upper flange which is bent away from said main body portion in a direction toward the building wall and is arcuately curved so as to be pivotally received within an arcuately curved recess of said mounting strip, said hanger also having a lower flange which is turned outward from said hanger main body portion in a direction away from the building wall so as to be supportingly attached to the undersides of said pans; and

an elongated flashing having a rectangular main body portion adapted to be substantially horizontally disposed so as to extend over the upper edges of said pans adjacent said mounting strip, said flashing also having a longitudinal flange which is arcuately 5 curved and received within the arcuately curved flange of said hanger;

whereby said hanger and said flashing together provide a substantially U-shaped box enclosing the upper ends of said pans, and said arcuately curved flanges of said hanger and said flashing are adapted to pivot as a unit within the arcuately curved recess of said mounting strip so as to permit the awning structure to pivot relative to the mounting strip in response to wind pressure and the like and at the same time provide a water-proof joint with the mounting strip but without imposing any mechanical stress upon the water-proof seal of said mounting strip to the wall.

3. In an awning structure, a horizontal mounting strip having an outwardly opening curved recess, a hanger having an essentially Z-shaped cross-sectional configuration with one-longitudinal edge thereof being arcuately curved and received within said recess to provide a tightly pivoting nesting relationship therewith, and an elongated flashing having an arcuately curved longitudinal edge received within said curved edge of said hanger to provide a tightly pivoting nesting relationship therewith; said hanger and flashing being adapted to pivot as a unit relative to said mounting strip while providing a leak-proof joint therewith.

4. The awning structure of claim 3 wherein the outwardly opening curved recess of said mounting strip is laterally curved through an angle of at least 180.

5. The awning structure of claim 3 which includes a plurality of flashing sections arranged in a longitudinal series and supported from a single hanger section.

6. The awning structure of claim 5 wherein the joining portions of said flashing sections arranged in a longitudinal series'are supported from a single hanger section, the joining portions of said flashing sections being butted together in end-to-end relationship, the pan covering portions of said flashing sections being longer than the joining portions so that each section overlaps 45 the preceding and following sections. 

1. An awning structure attached to the wall of a pre-existing building comprising, in combination: a mounting strip extending horizontally along the wall of the building, said mounting strip having a curved recess opening outwardly from the building; means attaching said mounting strip to the building wall, and providing a water-proof seal between the mounting strip and the wall; a plurality of generally trough-shaped pans arranged in a side-by-side relationship having the upper edges of their inner end approximately aligned with said recess of said mounting strip, and inclining outwardly and somewhat downwardly so that their outer ends may be supported by other means, the adjacent ones of said pans being joined together by means of overlapping and interlocking edges which provide an essentially water-proof joint between them; and a hat assembly for securing the inner ends of said pans to said mounting strip, while concurrently permitting the upper ends of said pans to pivot relative to said mounting strip in response to wind pressure and the like without breaking said seal, said hat assembly including: a. an elongated hanger having an arcuately curved flange received within said recess of said mounting strip, a flat portion extending downwardly from said flange to close the inner ends of said pan, and a lower flange bent outwardly from said main section of said hanger and secured to the bottom edges of the pans; and b. an elongated flashing having an arcuately curved flange received within said flange of said hanger, said flashing having a flat portion extending over the upper edges of said pans whereby said hanger and said flashing together comprise a U-shaped box which encloses the upper ends of said pans and is capable of pivoting as a unit relative to said mounting strip; said hanger flange and said flashing flange forming a water-tight joint with said mounting strip.
 1. An awning structure attached to the wall of a pre-existing building comprising, in combination: a mounting strip extending horizontally along the wall of the building, said mounting strip having a curved recess opening outwardly from the building; means attaching said mounting strip to the building wall, and providing a water-proof seal between the mounting strip and the wall; a plurality of generally trough-shaped pans arranged in a sideby-side relationship having the upper edges of their inner end approximately aligned with said recess of said mounting strip, and inclining outwardly and somewhat downwardly so that their outer ends may be supported by other means, the adjacent ones of said pans being joined together by means of overlapping and interlocking edges which provide an essentially water-proof joint between them; and a hat assembly for securing the inner ends of said pans to said mounting strip, while concurrently permitting the upper ends of said pans to pivot relative to said mounting strip in response to wind pressure and the like without breaking said seal, said hat assembly including: a. an elongated hanger having an arcuately curved flange received within said recess of said mounting strip, a flat portion extending downwardly from said flange to close the inner ends of said pan, and a lower flange bent outwardly from said main section of said hanger and secured to the bottom edges of the pans; and b. an elongated flashing having an arcuately curved flange received within said flange of said hanger, said flashing having a flat portion extending over the upper edges of said pans whereby said hanger and said flashing together comprise a U-shaped box which encloses the upper ends of said pans and is capable of pivoting as a unit relative to said mounting strip; said hanger flange and said flashing flange forming a watertight joint with said mounting strip.
 2. In an awning structure having a horizontal mounting strip attached by a water-proof seal to the outer wall of a building and a plurality of generally trough-shaped pans extending perpendicular to the mounting strip and arranged in side-by-side relationship with their abutting edges secured by water-proof joints, a hat assembly for providing water-proof enclosure of the upper ends of said pans while concurrently supporting said pans from said mounting strip in a pivotally yieldable but leak-Proof connection thereto, said hat assembly comprising, in combination: a hanger having a flat rectangular main body portion adapted to be substantially vertically disposed and to extend across the upper ends of said pans to provide an enclosure thereof, said hanger also having an upper flange which is bent away from said main body portion in a direction toward the building wall and is arcuately curved so as to be pivotally received within an arcuately curved recess of said mounting strip, said hanger also having a lower flange which is turned outward from said hanger main body portion in a direction away from the building wall so as to be supportingly attached to the undersides of said pans; and an elongated flashing having a rectangular main body portion adapted to be substantially horizontally disposed so as to extend over the upper edges of said pans adjacent said mounting strip, said flashing also having a longitudinal flange which is arcuately curved and received within the arcuately curved flange of said hanger; whereby said hanger and said flashing together provide a substantially U-shaped box enclosing the upper ends of said pans, and said arcuately curved flanges of said hanger and said flashing are adapted to pivot as a unit within the arcuately curved recess of said mounting strip so as to permit the awning structure to pivot relative to the mounting strip in response to wind pressure and the like and at the same time provide a water-proof joint with the mounting strip but without imposing any mechanical stress upon the water-proof seal of said mounting strip to the wall.
 3. In an awning structure, a horizontal mounting strip having an outwardly opening curved recess, a hanger having an essentially Z-shaped cross-sectional configuration with one longitudinal edge thereof being arcuately curved and received within said recess to provide a tightly pivoting nesting relationship therewith, and an elongated flashing having an arcuately curved longitudinal edge received within said curved edge of said hanger to provide a tightly pivoting nesting relationship therewith; said hanger and flashing being adapted to pivot as a unit relative to said mounting strip while providing a leak-proof joint therewith.
 4. The awning structure of claim 3 wherein the outwardly opening curved recess of said mounting strip is laterally curved through an angle of at least 180*.
 5. The awning structure of claim 3 which includes a plurality of flashing sections arranged in a longitudinal series and supported from a single hanger section. 